Pocketed spring assembly having multi-layered impermeable fabric

ABSTRACT

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. Each string is joined to at least one adjacent string. Each string has first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse segmented seams joining the plies. Gaps between the segments of the seams allow air to pass into and out of the pockets despite the fabric being impermeable to airflow through the fabric. The fabric has at least four layers. The size of the gaps determines the firmness or “feel” of the pocketed spring assembly or portion thereof.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/584,402 filed May 2, 2017, which is a continuation-in-partof U.S. patent application Ser. No. 15/062,595 filed Mar. 7, 2016. Eachof these applications is fully incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates generally to fabric for use in bedding andseating products and, more particularly, for use in pocketed springassemblies used in bedding and seating products.

BACKGROUND OF THE INVENTION

Mattress spring core construction over the years has been a continuouslyimproving art with advancements in materials and machine technology. Awell-known form of spring core construction is known as a Marshallspring construction wherein metal coil springs are encapsulated inindividual pockets of fabric and formed as elongate or continuousstrings of pocketed coil springs. In an earlier form, these strings ofcoil springs were manufactured by folding an elongate piece of fabric inhalf lengthwise to form two plies of fabric and stitching transverse andlongitudinal seams to join the plies of fabric to define pockets withinwhich the springs were enveloped.

More recently, improvements in spring core constructions have involvedthe use of fabrics which are thermally or ultrasonically weldable tothemselves. By using such welding techniques, these fabrics have beenadvantageously used to create strings of individually pocketed coilsprings wherein transverse and longitudinal welds, instead of stitching,are used to form the pockets encapsulating the springs. A fabric whichhas been used and proven to ultrasonically weld to itself is a non-wovenpolypropylene fabric which is extremely permeable to airflow. In otherwords, air may freely flow through the non-woven polypropylene fabric.

Once strings of pocketed springs are constructed, they may be assembledto form a spring core construction for a mattress, cushion or the likeby a variety of methods. For example, multiple or continuous strings maybe arranged in a row pattern corresponding to the desired size and shapeof a mattress or the like, and adjacent rows of strings may beinterconnected by a variety of methods. The result is a unitary assemblyof pocketed coil springs serving as a complete spring core assembly.

Spring cores may be generally covered on the top and often on the bottomby pads of resilient foam as, for example, a pad of urethane orlatex/urethane mix of foamed material. Within the last several years,more expensive cushions or mattresses have had the spring cores coveredby a visco-elastic foam pad, which is slow-acting or latex foam, whichis faster-acting, than visco-elastic foam. That is, the visco-elasticfoam pad is slow to compress under load and slow to recover to itsoriginal height when the load is removed from the visco-elastic foampad. These visco-elastic pads, as well as the latex pads, impart aso-called luxury feel to the mattress or cushion. These pads also,because of their open cell structure, retain heat and are slow todissipate body heat when a person sits or lies atop such a foampad-containing cushion or mattress.

Individually pocketed spring cores have been made with fabric materialwhich causes the pocketed spring core to depress slowly when a load isapplied and rise slowly when the load is removed, thereby imparting aluxury feel to the user of a bedding or seating product, such as amattress. Bedding or seating products, such as mattresses, made of suchfabric may have a feel like the feel of a product incorporatingviscoelastic or memory foam, but without the foam and its associatedcost and heat. A bedding or seating product having such a feel is knownin the industry as a slow recovery bedding or seating product.

One known method of creating a pocketed spring assembly having a slowrecovery feel is to perforate the fabric such that air passes throughthe perforations.

Another known method of creating a pocketed spring assembly having aslow recovery feel is to coat a known fabric to make the coated fabricsemi-impermeable to airflow through the coated fabric, as disclosed inU.S. Pat. No. 7,636,972, which is fully incorporated herein. Such fabricmay comprise a base layer having one or more layers of material sprayedor coated thereon to retard the rate of compression and expansion of thepocketed springs. The permeability of the coated fabric is retarded suchthat when a load is placed on a pocketed spring assembly made with suchsemi-impermeable fabric, the rate at which the pocketed spring assemblycompresses is slowed. Similarly, when a load is removed from thepocketed spring assembly, the rate of expansion of the pocketed springsis slowed.

Making a pocketed spring assembly with coated semi-impermeable fabricmay be challenging in an industrial setting. Because imparting a uniformcoating is difficult, the proper air permeability value is difficult tomaintain. Further, coated semi-impermeable fabric contains layers whichmay not be conducive to ultrasonic welding which may make weldconsistency challenging. Another drawback of a pocketed spring assemblymade from coated fabric is that the resultant semi-impermeable fabric ofthe pocket may create “noise”, as the sound is named in the industry.Such noise may be created by the fabric expanding upon removal of theload clue to the coil spring's upwardly directed force on the fabric.

Regardless of which manufacturing method is used to create asemi-impermeable pocketed spring assembly, the flow rate of air exitingor entering the pockets is constant regardless of the load applied tothe pockets. The perforations in the fabric do not adjust and react tothe load being applied to the pocket(s) of strings of the pocketedspring assembly. The inability of the fabric pockets to adjust air flowrates is a problem when considering pressure impulses, for example thosecaused by someone jumping on the bed or cushion containing a pocketedspring assembly made with known semi-impermeable fabric.

It is therefore an objective of this invention to provide a pocketedspring assembly made, at least partially with fabric impervious toairflow through the fabric, but which allows air to enter and exit thepockets at different flow rates in reaction to different loads beingapplied to one or more pockets.

It is further an objective of this invention to provide a pocketedspring assembly made, at least partially with fabric impervious toairflow through the fabric, but may allow air to enter and exit thepockets via gaps in the seams of the pockets.

It is therefore an objective of this invention to provide a fabric for apocketed spring assembly which is impervious to airflow through thefabric, but may be secured to itself consistently with segmented seams.

It is another objective of this invention to provide a method of makinga fabric for a pocketed spring assembly which ultrasonically welds toitself, impervious to airflow through the fabric, and quiet.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a bedding or seatingproduct incorporates a novel pocketed spring assembly. The pocketedspring assembly comprises a plurality of parallel strings of springsjoined together. Each string is joined to at least one adjacent string.Each string comprises a plurality of aligned individually pocketedsprings. Each string comprises a piece of fabric folded around multiplesprings to create first and second opposed plies of fabric on oppositesides of the springs. Opposed edges of the piece of fabric are joinedtogether along a longitudinal seam which may extend along one of thesides of the string of springs. Pockets are formed along the length ofthe string of springs by transverse or separating seams joining thefirst and second plies, at least one spring being positioned in eachpocket. The piece of fabric is impermeable to airflow and comprisesmultiple layers including a sound attenuation layer between layers ofnon-woven polypropylene.

In the illustrated embodiment, each of the seams is segmented, thefabric being welded to itself along segments of the seam. Each of thesegmented seams has gaps between the segments of the seams. Upon beingsubjected to a load, air inside a pocket exits the pocket through thegaps between the seam segments. Upon being subjected to a load the gapsincrease in size, allowing more air inside the pocket to exit thepocket.

It is within the scope of the invention that only some of the seams besegmented. In other words, some of the seams or portions thereof may besolid seams without segments and gaps between the segments for air toflow through. In such a pocketed spring assembly, some of seams, orportions thereof, may be segmented with gaps between seam segments. Suchsolid seams may be mixed with segmented seams in any desired fashion tocreate a desired airflow pattern.

At least some of the segmented seams, or portions thereof, have gapsbetween segments of the seams, such that upon being subjected to a loadthe gaps increase in size, allowing more air inside the pocket to exitthe pocket. Upon the load being removed, air enters a pocket throughgaps between the seam segments, or portions thereof. Once a pocket issufficiently full of air, the gaps of the segmented seams, or portionsthereof, may be smaller in size than when the pocket was under a load.In such a relaxed condition or state little air, if any, flows throughthe gaps of the segmented seams, or portions thereof, until another loadis placed on the pocket or an adjacent pocket(s) to increase the size ofthe affected gaps.

The bedding or seating product may further comprise cushioning materialand an upholstered covering encasing the pocketed spring assembly andcushioning materials.

The strings of springs may extend longitudinally (head-to-foot) ortransversely (side-to-side). Regardless of the orientation of theparallel strings of springs, a bedding or seating product may beposturized into regions or zones of different firmness by incorporatingdifferent strings of springs into the product.

If the strings of springs extend longitudinally, a bedding product mayinclude a plurality of the strings of springs having different airflowsbetween gaps in the seams, or portions thereof, between adjacentpockets. For example, the product may include two such zones; a “his”side and a “hers” side. The “hers” side, or zone, may have strings ofsprings having larger gaps in the transverse seams, or portions thereof,than the gaps of the transverse seams, or portions thereof, of thestrings of springs in the “his” side of the product. The result may beincreased airflow through gaps in the seams, or portions thereof, in the“hers” side of the product, resulting in a softer zone or region thanthe “his” side or zone. By incorporating strings of springs havingdifferent airflow characteristics through the gaps in the seams, orportions of the seams, into different zones or regions of a pocketedspring assembly, different zones or regions of a product may havedifferent feels or firmnesses.

According to another aspect of the invention, the pocketed springassembly comprises a plurality of parallel strings of springs joinedtogether. Although the pocketed spring assembly is typically used inbedding or seating products, the pocketed spring assembly may be used inany product. Each of the strings of springs comprises a plurality ofindividually pocketed springs. Each of the strings of springs comprisesa piece of fabric joined along a longitudinal seam, first and secondopposed plies of fabric being on opposite sides of the springs. Pocketsare formed along a length of the string of springs by transverse seamsjoining the first and second plies, at least one spring being positionedin each pocket. The piece of fabric is impermeable to airflow, but uponthe pocket being subjected to a load, air inside the pocket exits thepocket through gaps between segments of one or more seams, or portionsthereof.

The piece of fabric used to make a string of springs may be made ofmultiple layers. In one preferred embodiment, the fabric comprises atleast four layers: a first protective layer made of polypropylenenon-woven material or other suitable material; a second layerimpermeable to airflow which may be made of thermoplastic polyurethanefilm or other suitable material; a third sound attenuating or dampeninglayer secured to the second and fourth layers to prevent noise when thepocketed spring assembly is compressed and expanded and a fourth layermade of polypropylene non-woven material or other suitable material. Inmany circumstances, the first and fourth outer layers of the fabric maybe the same material, but do not necessary have to be identical. Thethird layer may be made of lofted needle punch polyester fiber battingor similar material such as polyurethane foam, for example. The secondand third layers may be glued or laminated together. In some instances,all adjacent layers may be glued or laminated together. When the pieceof fabric is wrapped around spaced springs and ultrasonically welded toitself along seams, partially or entirely segmented, to form a string,the first protective layer is closest to the springs on the inside ofthe string and the fourth protective layer is furthest away from thesprings on the outside of the string. The second layer sandwichedbetween the first and third layers preventing air from entering orexiting the pockets except via gaps in the segmented seams. The secondor middle layer is flexible and substantially impermeable to air flow.In some embodiments, all the layers are laminated together.

According to another aspect of the invention, a method of making afabric for use in a pocketed spring assembly is provided. The methodcomprises creating a stack comprising opposed layers of protectivematerial such as polypropylene non-woven material, a sound attenuatinglayer of lofted needle punch polyester fiber batting, a glue layer and alayer of thermoplastic polyurethane film impermeable to airflow. Thenext step comprises passing the stack through a laminator to melt theglue to secure the sound attenuating layer of lofted needle punchpolyester fiber batting to one side of the impermeable layer ofthermoplastic polyurethane film. If desired, an additional layer of gluemay be placed in the stack between the first protective layer ofpolypropylene non-woven material and the layer of thermoplasticpolyurethane film to join them together. Likewise, an additional layerof glue may be placed in the stack between the fourth or outermostprotective layer of polypropylene non-woven material and the soundattenuating layer of lofted needle punch polyester fiber batting. Themulti-layered finished fabric may be rolled up for storage to be usedlater. Alternatively, the finished fabric may be immediately cut to adesired size.

According to another aspect of the invention, a method of making apocketed spring assembly for use in a bedding or seating product isprovided. The method comprises joining a plurality of parallel stringsof springs together. Each of the strings of springs comprises aplurality of individually pocketed springs. Each of the strings ofsprings further comprises a piece of fabric joined along a longitudinalseam, first and second opposed plies of fabric being on opposite sidesof the springs. Pockets are formed along a length of the string ofsprings by transverse segmented seams joining the first and secondplies. At least one spring is positioned in each pocket. The piece offabric is impermeable to airflow, but air inside the pocket exits andair enters the pocket through gaps between segments along one or more ofthe seams, or portions thereof.

The piece of fabric comprises a unitary fabric having at least fourjoined layers: at least two outer protective layers of polypropylenenon-woven material, at least one layer of thermoplastic polyurethanefilm impermeable to airflow, and at least one sound attenuating orquieting layer such as lofted needle punch polyester fiber batting. Thepiece of fabric is oriented such that one of the outer protective layersof polypropylene non-woven material is closest to the springs orresilient members inside the pockets of the string and the other isfurthest away from the springs or resilient members.

The multi-layered fabric pockets of the present invention provide aconsistent luxurious feel regardless of the load placed on the pockets.The ability of the pockets to react to different loads placed thereon bychanging the amount of air flow through adjacent pocket and/or out ofstrings produce a luxurious slow recovery feel regardless of the loadplaced on the pocketed spring assembly or portion thereof. The valves ofthe pocketed spring assembly of the present invention prevent the middlelayer of film from rupture even when a heavy load is applied suddenly,such as when a heavy person jumps on a bed or sits on a cushioncontaining a pocketed spring assembly at least partially made from thefabric of the present invention.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with the summary of the invention given above, and the detaileddescription of the drawings given below, explain the principles of thepresent invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, partially broken away, of a bedding orseating product incorporating a pocketed spring assembly according tothe principles of the present invention.

FIG. 1A is a perspective view, partially broken away, of a bedding orseating product incorporating another pocketed spring assembly.

FIG. 1B is a perspective view, partially broken away, of another beddingproduct incorporating the pocketed spring assembly of FIG. 1A.

FIG. 1C is a perspective view, partially broken away, of two-sidedbedding product incorporating the pocketed spring assembly of FIG. 1A.

FIG. 2A is a partial side view of one of the strings of springs of thepocketed spring assembly of FIG. 1 being compressed.

FIG. 2B is a partial side view of the strings of springs of FIG. 2Aexpanding.

FIG. 3 is a perspective view, partially broken away, of a portion of oneof the strings of springs of FIG. 1, in an unloaded condition.

FIG. 4A is a top view of a pocketed spring assembly.

FIG. 4B is a top view of another pocketed spring assembly.

FIG. 5A is a top view of a posturized pocketed spring assembly.

FIG. 5B is a top view of another posturized pocketed spring assembly.

FIG. 5C is a top view of another pocketed spring assembly.

FIG. 5D is a top view of another posturized pocketed spring assembly.

FIG. 6 is a side elevational view of an apparatus for practicing one ofthe methods of making one of the fabrics of the present invention.

FIG. 7 is an enlarged view of the encircled area 7 of FIG. 6.

FIG. 8 is a side elevational view of another apparatus for practicingone of the methods of making one of the fabrics of the presentinvention.

FIG. 9 is a side elevational view of an apparatus for practicing one ofthe methods of making one of the fabrics of the present invention.

FIG. 10 is a perspective view of a portion of an ultrasonic laminatorlaminating three webs of material into a unitary three-layered fabric.

FIG. 11 is an enlarged view of the encircled area 11 of FIG. 10.

FIG. 12A is a partial end view of one of the strings of springs of thepocketed spring assembly of FIG. 1 in an ambient state.

FIG. 12B is a partial end view of the strings of springs of FIG. 12Abeing compressed.

FIG. 12C is a partial end view of the strings of springs of FIG. 12Abeing further compressed.

FIG. 13 is a perspective view, partially broken away, of a portion ofanother embodiment of strings of springs, in an unloaded condition.

FIG. 14 is a side elevational view of an apparatus for practicing one ofthe methods of making one of the fabrics of the present invention.

FIG. 15 is an enlarged view of the encircled area 15 of FIG. 14.

FIG. 16 is a side elevational view of an apparatus for practicing one ofthe methods of making one of the fabrics of the present invention.

FIG. 17 is a perspective view of a portion of an ultrasonic laminatorlaminating four webs of material into a unitary four-layered fabric.

FIG. 18 is an enlarged view of the encircled area 18 of FIG. 17.

DETAILED DESCRIPTION OF THE INVENTION

Referring first to FIG. 1, there is illustrated a bedding product in theform of a single-sided mattress 10 incorporating the principles of thepresent invention. This product or mattress 10 comprises a pocketedspring assembly 12 over the top of which lays conventional padding orcushioning layers 14, 16 which may be foam, fiber, gel, a pocketedspring blanket, one or more scrim sheets or any other suitable materialsor any combination thereof. The pocketed spring assembly 12 may besurrounded with a border 17 made of foam or any other suitable material(only a portion being shown in FIG. 1). Although one type of border 17is illustrated in FIGS. 1, 1A, 1B and 1C, the border may assume otherforms or shapes of any desired size, such as pocketed coil springs. Inplace of a foam border, it has become common to at least partiallysurround a pocketed spring assembly with springs of a different diameteror height than the pocketed springs of the interior of the pocketedspring assembly. In any product shown or described herein incorporatingany embodiment of pocketed spring assembly shown or described herein, aborder may be omitted.

Pocketed spring assembly 12 resides upon a base 18 and all componentsenclosed within an upholstered covering material 20. The base 18 andborder 17 are known in the industry as a “bucket” into which a pocketedspring assembly 12 is inserted before the “bucket” is covered with oneor more padding or cushioning layers. The base 18 may be foam, a scrimsheet, a piece of plastic, wood or any other known material.

As shown in FIG. 1, fully assembled, the product 10 has a length “L”defined as the linear distance between opposed end surfaces 22 (only onebeing shown in FIG. 1). Similarly, the assembled product 10 has a width“W” defined as the linear distance between opposed side surfaces 24(only one being shown in FIG. 1). In the product shown in FIG. 1, thelength is illustrated as being greater than the width. However, it iswithin the scope of the present invention that the length and width maybe identical, as in a square product.

As shown in FIGS. 1 and 2, pocketed spring assembly 12 is manufacturedfrom multiple strings 26 of pocketed springs 28 joined together. Inpocketed spring assembly 12 shown in FIG. 1, each string 26 of pocketedsprings 28 extends longitudinally or from head-to-foot along the fulllength of the pocketed spring assembly 12. Although the strings 26 ofpocketed springs 28 are illustrated as extending longitudinally or fromhead-to-foot in the pocketed spring assembly 12 of FIG. 1, they mayextend transversely or from side-to-side as shown in a pocketed springassembly 12 a shown in the products 10 a, 10 c shown in FIGS. 1A and 1C,respectively. The pocketed spring assembly 12 a comprises multiplestrings 26 a of pocketed springs 28, identical to the strings of springs26, but shorter in length. In any of the embodiments shown or describedherein, the strings may extend either longitudinally (from end-to-end)or transversely (from side-to-side).

FIG. 1B illustrates a single-sided mattress 10 b comprising a pocketedspring assembly 12 and border 17 identical to those shown in themattress 10 of FIG. 1. However, the mattress 10 b of FIG. 1B has apocketed topper 30 employing miniature or small coil springsindividually pocketed, in addition to padding layers 14 above and belowthe pocketed topper 30. Although one configuration of pocketed topper 30is illustrated, any pocketed topper known in the art may be used, suchas the ones disclosed in U.S. Pat. Nos. 9,943,173 and 9,968,202, each ofwhich is fully incorporated by reference herein.

FIG. 1C illustrates a double-sided mattress 10 c comprising a pocketedspring assembly 12 a and border 17. The mattress 10 c of FIG. 1B haspocketed toppers 30 above and below the pocketed spring assembly 12 a inaddition to padding layers 14 above and below each pocketed topper 30.While the mattresses 10, 10 a and 10 b illustrated in FIGS. 1, 1A and1B, respectively, are single-sided mattresses, any pocketed springassembly shown or described herein may be incorporated into any beddingor seating product shown or described herein, including a double-sidedmattress or seating cushion, such as the mattress 10 c shown in FIG. 1C.If desired, any of the padding or cushioning layers, including one ormore pocketed topper 30, may be omitted in any of the embodiments shownor described herein.

Strings of pocketed springs 26, 26 a and any other strings of springsdescribed or shown herein, may be connected in side-by-side relationshipas, for example, by gluing the sides of the strings together in anassembly machine, to create an assembly or matrix of springs havingmultiple rows and columns of pocketed springs bound together as bygluing, welding or any other conventional assembly process commonly usedto create pocketed spring cores or assemblies.

Referring to FIG. 4A, the longitudinally extending strings 26 ofpocketed spring assembly 12, along with any other strings described orshown herein, including transversely extending strings 26 a of pocketedspring assembly 12 a, may be joined so that the individually pocketedsprings 28 are aligned in transversely extending rows 32 (extending fromside-to-side) and longitudinally extending columns 34 (extending fromhead-to-foot).

Alternatively, as shown in FIG. 4B, the longitudinally extending strings26 of pocketed spring assembly 12 b, along with any other stringsdescribed or shown herein, including transversely extending strings 26 aof pocketed spring assembly 12 a, may be offset from one another. Insuch an arrangement, shown in FIG. 4B, the individually pocketed springs28 are not aligned in rows and columns; instead the individuallypocketed springs 28 fill voids 36 of the adjacent strings. Eitheralignment of strings may be incorporated into any of the pocketed springassemblies or cores illustrated or described herein.

FIG. 2A illustrates a partial side view of an end portion of one of thestrings 26 of pocketed springs 28 of pocketed spring assembly 12 beingcompressed or under an external load. FIG. 2B illustrates a partial sideview of the portion of string 26 of pocketed springs 28 of FIG. 2A beinguncompressed or after removal of the external load moving towards arelaxed condition. FIG. 3 is a perspective view of the portion of thestring 26 of pocketed springs 28 of FIG. 2A in a relaxed condition underno external load.

As best illustrated in FIGS. 2A, 2B and 3, each string 26 of pocketedsprings 28 comprises a row of interconnected fabric pockets 38. Each ofthe fabric pockets 38 contains at least one resilient member, such as acoil spring 40. The resilient member need not be a coil spring; it maybe made of foam or other resilient material. The coil spring 40 ispreferably made of one piece of wire of a uniform diameter, but may bemade of other materials, multiple strands of twisted wire and/or may bea non-uniform diameter, such as a barrel-shaped spring.

As best shown in FIG. 3, each coil spring 40 has a central orlongitudinal axis A, an upper end turn 42, a lower end turn 44 and aplurality of central convolutions 46 between the end turns. FIGS. 2A, 2Band 3 illustrate a coil spring 40 in which the diameter of the end turns42, 44 is generally identical to the diameter of the centralconvolutions 46. However, any known coil spring may be used inside anythe fabric pockets 38. Not all coil springs within a pocketed springassembly need be identical, although they are most of the time. Thepocketed spring assembly of the present invention may use pieces of foamor other resilient members, rather than coil springs. One or morepockets may have more than one spring, such as a coil spring with atleast cushion such as a foam insert inside, above or below the coilspring or any combination thereof.

Preferably, one piece of fabric is used to create the string of pocketedsprings 26. The piece of fabric is impermeable to airflow through thefabric itself due to at least one of several layers of the fabric beingimpermeable to airflow through the fabric, as described herein. Airmoves between adjacent fabric pockets 38 and into and out of the string26 only through gaps or valves along the seams or portions of the seams.

The piece of fabric is folded over onto itself around multiple coilsprings 40. As best shown in FIG. 3, opposite sides or plies 48, 50 ofthe fabric are welded or otherwise secured together in segments tocreate a longitudinal segmented seam 52 and a plurality of separating ortransverse segmented seams 54. FIG. 3 illustrates ply 48 being closestto the reader and ply 50 being behind the coil springs 40.

As best shown in FIG. 3, opposed edges 56 of the piece of fabric used tocreate the string of pocketed springs 26 are aligned and spaced from thelongitudinal side seam 52 a distance indicated by numeral 58. Althoughthe drawings indicated the longitudinal seam 52 being below the freeedges 56 of the piece of fabric, the longitudinal seam 52 may be abovethe free edges 56 of the piece of fabric. This is known in the industryas a side seam of a string of springs.

As shown in FIG. 3, in the absence of being subjected to a load, thestring of pocketed springs 26 has a generally planar top surface 60 in atop plane P1 and a parallel generally planar bottom surface 62 in abottom plane P2. The linear distance between the top and bottom surfacesof the string of pocketed springs 26 defines a height H of the string ofpocketed springs 26. This linear distance further defines the height Hof the pocketed spring assembly 12 because each of the strings ofsprings 26 has the same height. However, it is within the contemplationof the present invention that the strings of springs be differentheights.

As best shown in FIGS. 2A, 2B and 3, the longitudinal seam 52 comprisesmultiple spaced linear weld segments 64 formed using an ultrasonicwelding horn and anvil (not shown) as disclosed in U.S. patentapplication Ser. No. 15/062,318. Gaps or valves 66 are located betweenadjacent linear weld segments 64 to allow air to flow between the weldsegments 64, as shown by the arrows 77, 79 of FIGS. 2A and 2B,respectively.

Depending upon the airflow desired into and out of the fabric pockets 38of a string 26 or 26 a, at least some of the longitudinal seams 52 of astring may not be segmented or be only partially segmented. For example,the longitudinal seam 52 of a string of springs may not be segmented atall, provided the transverse or separating seams 54 are at leastpartially segmented to allow airflow into and out of the fabric pockets.

As best shown in FIGS. 2A, 2B and 3, each transverse or separating seam54 comprises multiple spaced linear weld segments 68 formed using anultrasonic welding horn and anvil (not shown) to join the opposed plies48, 50 of fabric as disclosed in U.S. patent application Ser. No.15/062,318. Gaps or valves 70 are located between adjacent linear weldsegments 68 to allow air to flow between the weld segments 68.

Depending upon the airflow desired into and out of the fabric pockets 38of a string 26, 26 a, at least some of the transverse or separatingseams 54 of a string may not be segmented or may be only partiallysegmented. For example, one or more transverse seams 54 of a string maybe partially segmented or not be segmented at all, provided thelongitudinal seam 52 is at least partially segmented to allow airflowinto and out of the fabric pockets.

As shown in FIG. 2A, when a load is exerted on a pocketed spring 28 of astring 26, as shown by arrows 72, air exits the pocket 38 through gaps70 between adjacent weld segments 68 of the transverse or separatingseams 54 because the multi-layered fabric is impermeable to airflow. Seeairflow shown by arrows 75. Air passes through gaps 70 between adjacentfabric pockets 38 and out of the string 26 through gaps 70 of theoutermost or end transverse or separating seams 54 of the strings ofsprings 26.

Additionally, air may exit the fabric pocket 38 through gaps 66 betweenthe weld segments 64 of the longitudinal seam 52. See airflow shown byarrows 77. As shown in FIG. 2A, the size of the gaps 70 between the weldsegments 68 of transverse or separating seams 54, along with the size ofthe gaps 66 between the weld segments 64 of the longitudinal seam 52 ofthe pockets 38, define how quickly air may exit the pocket 38. Air doesnot exit the pockets 38 other than through the gaps since the fabric isimpermeable to airflow. Different strings of springs may have differentperformance characteristics based on the size of the gaps 70 in thetransverse or separating seams 54 and/or the gaps 66 in the longitudinalseam 52 or any combination thereof. Depending upon this airflow, thestrings of springs made with such fabric impermeable to airflow mayimpart different firmness characteristics upon the user or personimparting a load on the string of springs.

As shown in FIG. 2B, when a load is removed from the fabric pocket 38,the coil spring 40 raises the fabric pocket 38 upwardly in the directionof arrows 74. Air re-enters the pocket 38 through the gaps 70 betweenthe weld segments 68 of the transverse or separating seams 54 becausethe fabric is impermeable to airflow. See airflow shown by arrows 81.Air passes between fabric pockets 38 through these gaps 70 and into thestring 26 through the gaps 70 of the outermost or end transverse orseparating seams 54.

Additionally, air may enter the fabric pocket 38 through gaps 66 betweenthe weld segments 64 of the longitudinal seam 52. See airflow shown byarrows 79. As shown in FIG. 2B, the size of the gaps 70 between the weldsegments 68 of transverse or separating seams 54 along with the size ofthe gaps 66 between the weld segments 64 of the longitudinal seam 52 ofthe pockets 38 define how quickly air may enter the pockets 38. Air doesnot enter the pockets 38 other than through the gaps since the fabric isimpermeable to airflow.

Although the weld segments in the embodiments shown are illustrated asbeing heat-welded spaced rectangular-shaped segments, any of the seamsegments may be other shapes, such as spaced dots, ovals or triangles ofany desired sizes.

As shown in FIG. 3, the fabric material of each of the strings 26 isimpermeable to airflow through the fabric. The fabric comprises threelayers, including from the inside of the fabric pocket 38 outwardly asshown in FIG. 3: 1) a protective layer of fabric 76; 2) an airtightlayer 78 and 3) a sound attenuating or quieting layer 80. Morespecifically, the protective layer of fabric 76 may be a polypropylenenon-woven fabric layer having a density of approximately one ounce persquare yard commercially available from Atex, Incorporated ofGainesville, Ga. The airtight layer 78 may be a polyether thermoplasticpolyurethane film layer having a thickness of approximately 1.0 mil(0.001 inches) commercially available from American Polyfilm,Incorporated of Branford, Conn. The sound attenuating layer may be alofted needle punch polyester fiber batting layer having a density of0.5 ounces per square foot commercially available from Milliken &Company of Spartanburg, S.C.

These materials and material specifications, such as the densitiesprovided for the outer layers, have proven to be effective, but are notintended to be limiting. For example, the thickness of the impermeablemiddle layer of thermoplastic polyurethane film may vary depending uponthe desired characteristics of the multi-layered fabric. The citedthickness of 1.0 mil is not intended to be limiting. The soundattenuating layer need not be made of polyester; it may be made of othermaterials. Similarly, the fiber batting need not be lofted.

The middle thermoplastic polyurethane film layer 78 is impermeable toairflow. The lofted needle punch polyester fiber batting layer 80 actsas a sound dampening layer which quiets and muffles the film layer 78 asthe springs are released from a load (pressure in the pocket goes frompositive to negative) or loaded (pressure in the pocket goes fromneutral to positive). The polypropylene non-woven fabric layer 76 keepsthe segmented air passages open, such that the pocket 38 may “breathe”.Without the polypropylene non-woven fabric layer 76 closest to thesprings 40, the middle thermoplastic polyurethane film 78 would cling toitself and not allow enough air to pass through the segmented airpassages, valves or gaps in the seams. The polypropylene non-wovenfabric protective layer 76 closest to the springs also makes the productmore durable by protecting the airtight middle thermoplasticpolyurethane film layer 78 from contacting the spring 40 anddeteriorating from abrasion against the spring 40.

Although FIG. 3 illustrates a portion of a string of springs 26 used inpocketed spring assembly 12, the three-layered fabric impermeable toairflow may be used in any string of spring shown or described herein,such as strings of springs 26 a used in pocketed spring assembly 12 a.

FIG. 5A illustrates a posturized pocketed spring assembly 12 d havingdifferent zones or regions of different firmness. Pocketed springassembly 12 d comprises multiple longitudinally extending strings ofsprings 26 d, 26 dd joined together in one arrangement for a bedding orseating product, such as a mattress. As can be seen, the longitudinallyextending strings of springs 26 d, 26 dd are arranged into two zones orregions in the pocketed spring assembly 12 d. By way of example, twozones 82, 84 are illustrated, with the zones corresponding roughly to a“firm” zone or region 82 and a “soft” zone or region 84. Thelongitudinally extending strings of springs 26 d of the “firm” zone 82are each strings of springs constructed with the multi-layeredimpermeable fabric shown and described herein. The longitudinallyextending strings of springs 26 dd of the “soft” zone 84 are eachstrings of springs constructed with conventional single layer non-wovenpolypropylene fabric permeable to airflow through the fabric.

Referring now to FIG. 5B, transversely extending strings of springs 26e, 26 ee are shown in one preferable arrangement for a pocketed springassembly 12 e for a bedding or seating product, such as a mattress. Ascan be seen, the transversely extending strings of springs are arrangedin a plurality of zones in the pocketed spring assembly 12 e. By way ofexample, three zones are illustrated, with the zones correspondingroughly to the location of a sleeper's head and shoulders, mid-section,knees and feet. By way of further example, the two end “soft” zones 86each comprise strings of springs 26 ee constructed with conventionalsingle layer non-woven polypropylene fabric permeable to airflow throughthe fabric. The transversely extending strings of springs 26 e of themiddle or “firm” zone 88 are each strings of springs constructed withthe multi-layered impermeable fabric shown and described herein.

FIG. 5C illustrates another embodiment of pocketed spring assemblyincorporating strings of springs made with different fabrics. FIG. 5Cillustrates longitudinally extending strings of springs 26 f, 26 ffarranged in a pocketed spring assembly 12 f for a bedding or seatingproduct, such as a mattress. As can be seen, the longitudinallyextending strings of springs 26 f, 26 ff are arranged in an alternatingpattern in the pocketed spring assembly 12 f. As shown in FIG. 5C, eachlongitudinally extending string of springs 26 f of the pocketed springassembly 12 f is shaded, illustrating the string of springs isconstructed with the multi-layered impermeable fabric shown anddescribed herein. Every other longitudinally extending string of springs26 ff of the spring assembly is not shaded, illustrating the string ofsprings is constructed with conventional single layer non-wovenpolypropylene fabric permeable to airflow through the fabric.

FIG. 5D illustrates another embodiment of pocketed spring assembly 12 gincorporating strings of springs made with different fabrics. FIG. 5Dillustrates longitudinally extending strings of springs 26 g, 26 ggarranged in a pocketed spring assembly to provide edge support. As shownin FIG. 5D, the longitudinally extending strings of springs 26 g on theinterior of the spring assembly is shaded, illustrating the strings ofsprings is constructed with the multi-layered impermeable fabric shownand described herein. Two outermost longitudinally extending strings ofsprings 26 gg of the pocketed spring assembly along each side of thepocketed spring assembly 12 g are not shaded, illustrating each of thesestrings of springs is constructed with conventional single layernon-woven polypropylene fabric permeable to airflow through the fabric.Of course, the reverse may be true. One or two strings of springsextending along the sides of the pocketed spring assembly may be madeusing multi-layered impermeable fabric, and the interior strings ofsprings made using conventional single layer non-woven polypropylenefabric permeable to airflow.

FIG. 6 illustrates an apparatus 90 for conducting a method of making thefabric for use in the strings of springs shown and described herein orfor any other bedding or seating product, including the productsdescribed in U.S. Pat. No. 9,968,202.

Referring to FIG. 6, the method comprises providing a source 92 of thefirst protective layer of polypropylene non-woven fabric which may be aroll of polypropylene non-woven fabric or any other source. A web of theprotective polypropylene non-woven fabric 76 from the source 92 ispassed around a roller 94 and into a laminator 96. The method furthercomprises providing a source 98 of the middle airtight layer ofthermoplastic polyurethane film which may be a roll of the film or anyother source. A web of the airtight thermoplastic polyurethane film 78from the source 98 is passed around a roller 100 and into the laminator96. The method further comprises providing a source 102 of the thirdsound attenuating layer of lofted needle punch polyester fiber batting,which may be a roll of the batting or any other source. A web of thesound attenuating material such as lofted needle punch polyester fiberbatting 80 from source 102 is passed around a roller 104 and into thelaminator 96. The method further comprises providing a source 106 ofglue which may be a roll of the glue available from Hanes Industries ofConover, N.C. A web of the glue 108 from source 106 is passed around aroller 110 and into the laminator 96. The web of glue 108 is locatedbetween the web of sound attenuating material such as lofted needlepunch polyester fiber batting 80 and the web of airtight material suchas thermoplastic polyurethane film 78. Once inside the laminator 96, theweb of glue 108 is heated so it melts to secure the sound attenuatingweb of lofted needle punch polyester fiber batting 80 and the airtightweb of thermoplastic polyurethane film 78 together. Residual heat fromthe laminator 96 may temporarily secure the web of the polypropylenenon-woven fabric 76 to the middle airtight web of thermoplasticpolyurethane film 78 to create a three-layered web 112, which is passedbetween presser rollers 114 to further secure the three layers togetherinto a finished fabric 116 shown in detail in FIG. 7. As shown in FIG.6, a cutter 118 may be used to cut the finished fabric 116 to a desiredsize. Alternatively, the finished fabric 116 may be rolled into a roll120 after being cut.

FIG. 8 illustrates the same apparatus for practicing the method shown inFIG. 7, but with the addition of another source of glue and web of glueto further secure the three layers 76, 78 and 80 of the impermeablefabric 116 shown in FIG. 7 together. This method of manufacturing afinished web 116 further comprises providing a second source 124 ofglue, which may be a roll of the glue available from Hanes Industries ofConover, N.C. A web of the glue 126 from source 124 is passed around aroller 128 and into the laminator 96. The web of glue 126 is locatedbetween the protective web of polypropylene non-woven fabric 76 and theairtight web of thermoplastic polyurethane film 78. Once inside thelaminator 96, the web of glue 126 is heated so it melts to secure theweb of protective polypropylene non-woven fabric 76 and the airtight webof thermoplastic polyurethane film 78 together. Heat from the laminator96 melts each web of glue to create a three-layered web 112, which ispassed between presser rollers 114 to further secure the three layerstogether into the finished fabric 116 shown in detail in FIG. 7. Asshown in FIG. 6, a cutter 118 may be used to cut the finished fabric 116to a desired size. Alternatively, the finished fabric 116 may be rolledinto a roll 120 after being cut.

FIG. 9 illustrates a slightly different apparatus for practicing asimilar method of manufacturing the three-layered impermeable fabric 116shown in FIG. 7. This method of manufacturing finished three-layeredimpermeable fabric web 116 uses a glue sprayer 130, which may apply glueto one surface of the web of thermoplastic polyurethane film 78 betweenthe web of sound attenuating lofted needle punch polyester fiber batting80 and the airtight web of thermoplastic polyurethane film 78 beforeentering the laminator 96. Once inside the laminator 96, the glue may beheated so it melts to secure the web of sound attenuating lofted needlepunch polyester fiber batting 80 and the airtight web of thermoplasticpolyurethane film 78 together. Heat from the laminator 96 melts the glueto create a three-layered web 112, which is passed between presserrollers 114 to further secure the three layers together into thefinished fabric 116 shown in detail in FIG. 7. As shown in FIG. 6, acutter 118 may be used to cut the finished three-layered impermeablefabric 116 to a desired size. Alternatively, the finished three-layeredimpermeable fabric 116 may be rolled into a roll 120 after being cut.

Although not shown, a second sprayer may be incorporated into the systemor apparatus to apply glue to both sides of the airtight web ofthermoplastic polyurethane film 78 before the webs pass through thelaminator 96.

FIGS. 10 and 11 illustrate a different apparatus for practicing adifferent method of manufacturing the three-layered impermeable fabric136 shown in FIG. 11. This method of manufacturing finishedthree-layered impermeable fabric web 136 uses an ultrasonic laminator132, which may weld three incoming webs of material together withultrasonic welds 134. As shown in FIG. 10, the incoming protective webof polypropylene non-woven fabric 76 is welded to the airtight web ofthermoplastic polyurethane film 78 and the sound attenuating web oflofted needle punch polyester fiber batting 80. The ultrasonic laminator132 joins the three webs at select locations 134 to create athree-layered impermeable fabric web 136 shown in detail in FIG. 11. Asshown in FIG. 6, a cutter 118 may be used to cut the finishedthree-layered impermeable fabric web 136 to a desired size.Alternatively, the finished fabric 136 may be rolled into a roll asshown in FIGS. 6, 8 and 9.

FIGS. 12A, 12B and 12C illustrate another version of string 26′ whichmay be used in any pocketed spring assembly shown or described hereinand incorporated into any desired product. The string 26′ may be made ofany of the fabrics disclosed or shown herein. String 26′ functions inthe same manner as strings 26, 26 a shown and described herein. However,the longitudinal segmented seam 52′ and separating or transversesegmented seams 54′ are shaped differently. As in fabric pockets 38 ofstrings 26, 26 a described and shown herein, each fabric pocket 38′ ofstring 26′ has at least one coil spring 40 inside the fabric pocket 38′.

As shown in FIGS. 12A, 12B and 12C, the longitudinal seam 52′ of string26′ comprises multiple spaced linear weld segments 64′ formed using anultrasonic welding horn and anvil (not shown) as disclosed in U.S. Pat.No. 9,968,202. Gaps 66′ are located between adjacent linear weldsegments 64′ to allow air to flow through the gaps 66′ between the weldsegments 64′, as shown by the arrows 77′ of FIGS. 12B and 12C. Air mayflow out of the string 26′ through the gaps 66′ located between weldsegments 64′ of the longitudinal seam 52′ at different speeds dependingon the load placed upon the string 26′. Similarly, air may flow into thestring 26′ through the gaps 66′ located between weld segments 64′ of thelongitudinal seam 52′ at different speeds depending on the load removedfrom the string 26′. For purposes of tis document, the gaps 66′ betweenweld segments 64′ of the longitudinal seam 52′ of string 26′ may beconsidered valves which change in size depending on the load placed uponthe string 26′ or removed from the string 26′ to control air flow asdescribed below.

As shown in FIGS. 12A, 12B and 12C, each transverse seam 54′ of string26′ (only one being shown) comprises multiple spaced linear weldsegments 68′ formed using an ultrasonic welding horn and anvil (notshown) to join the opposed plies 48′, 50′ of fabric as disclosed in U.S.Pat. No. 9,968,202. Gaps or valves 70′ are located between adjacentlinear weld segments 68′ to allow air to flow between the weld segments68′. Air may flow through the gaps 70′ of the transverse seams 54′ ofstring 26′ between weld segments 68′ from one pocket 38′ to the adjacentpocket 38′. Air may flow into and out of the string 26′ through the gaps70′ of the outermost transverse seams 54′ at opposite ends of string26′, as shown by arrows 79′ in FIG. 12B. For purposes of this document,the gaps 70′ of the transverse seams 54′ of string 26′ may be consideredvalves which change in size depending on the load placed upon the string26′ or removed from the string 26′ to control air flow as describedbelow. Gaps 70′ of the transverse seams 54′ and gaps 66′ of thelongitudinal seam 52′ of string 26′ function as valves in controllingthe air flow into and out of the pockets 38′ of the string 26′ withoutany material or apparatus other than the multi-layered fabric of thestring 26′. The construction of the string 26′ has inherent valvestherein between seam segments, the valves controlling air flow into andout of the pockets 38′ of the string 26′ depending upon the size of theseam segments, the load(s) placed on the string 26′ and the compositionof the fabric material of the string 26′, among other factors.

FIG. 12A shows the string 26′ without any load placed on the string 26′.The string 26′ is in a relaxed condition. Air does not flow through thegaps 70′ of the transverse seams 54′ of string 26′ or through the gaps66′ of the longitudinal seam 52′. The air pressure inside the pockets38′ is at atmospheric pressure at ambient temperature so the valves 66′,70′ are in a relatively restrictive state, i.e. relatively flat. Theopposed plies 48′, 50′ of fabric of the transverse seams 54′ may becontacting each other or very close to each other. See FIG. 12A.

FIG. 12B shows the string 26′ with a light load placed on the string26′, as indicated by arrow 122. Once a light load is placed on thestring 26′, at least some of the valves or gaps 66′ of the longitudinalseam 52′ and/or at least some of the valves or gaps 70′ of thetransverse seams 54′ of string 26′ or any combination thereof openslightly so that air flows through at least some of the gaps 70′ of thetransverse seams 54′ of string 26′ and/or through at least some of thegaps 66′ of the longitudinal seam 52′ or any combination thereof.

FIG. 12C shows the string 26′ with a heavier load placed on the string26′, as indicated by the three arrows 123. Once a large load is placedon the string 26′, at least some of the valves or gaps 66′ of thelongitudinal seam 52′ and/or at least some of the valves or gaps 70′ ofthe transverse seams 54′ of string 26′ or any combination thereof openeven more so that more air flows through at least some of the gaps 70′of the transverse seams 54′ of string 26′ and/or through at least someof the gaps 66′ of the longitudinal seam 52′ or any combination thereof.

If a load, is applied to the string 26′ that is significantly greaterthan the load need to open the valves 70′ transverse seams 54′ andvalves 66′ of the longitudinal seam 52′, the fabric material of thestring 26′ will elastically stretch and open further to allow more airto pass through the valves or gaps in the seams. Thereby, the valvesreact to the specific load applied. Such reaction contributes to theunique luxurious feel of a pocketed spring assembly made from stringsmade in accordance with the present invention. The ability of the valvesto stretch and react to the air pressure is largely due to the middlethermoplastic polyurethane film layer. The middle thermoplasticpolyurethane film layer is a relatively elastic material which returnsto its original shape after a load is removed. When the load isreleased, the valves return to their original condition which is arelatively restrictive state in which the air pressure inside thepockets is at atmospheric pressure at ambient temperature.

It is within the contemplation of the present invention that only someof the strings of a pocketed spring assembly be made in accordance withthe present invention. For example, every other string may be made ofconventional fabric.

It is further within the scope of the present invention that thedifferent strings shown and described herein may be used together. Forexample, every other string may have segmented seams as shown in FIGS.12A, 12B and 12C and the other strings have segmented seams as shown anddescribed elsewhere in this document.

FIG. 13 illustrates a view like FIG. 3, but showing a different string26 b having a different fabric material than the strings 26 describedherein. For simplicity, like components are numbered the same. Strings26 b may be used in any embodiment shown or described herein. Thefour-layered fabric material of strings 26 b is impermeable to airflowthrough the fabric, like the three-layered fabric material of strings26. The fabric comprises four layers, including from the inside of thefabric pocket 38 outwardly as shown in FIG. 13: 1) an inner protectivelayer of fabric 76; 2) an airtight layer 78; 3) a sound attenuating orquieting layer 80; and 4) an outer protective layer of fabric 76.

The thermoplastic polyurethane film layer 78 is impermeable to airflow.The lofted needle punch polyester fiber batting layer 80 acts as a sounddampening layer which quiets and muffles the film layer 78 as thesprings are released from a load (pressure in the pocket goes frompositive to negative) or loaded (pressure in the pocket goes fromneutral to positive). The polypropylene non-woven fabric layers 76 keepthe segmented air passages open, such that the pocket 38 may “breathe”.Without the polypropylene non-woven fabric layer 76 closest to thesprings 40, the thermoplastic polyurethane film 78 would cling to itselfand not allow enough air to pass through the segmented air passages,valves or gaps in the seams. The polypropylene non-woven fabricprotective layer 76 closest to the springs also makes the product moredurable by protecting the airtight thermoplastic polyurethane film layer78 from contacting the spring 40 and deteriorating from abrasion againstthe spring 40. The polypropylene non-woven fabric protective layer 76furthest from the springs protects the lofted needle punch polyesterfiber batting layer 80.

Although FIG. 13 illustrates a portion of a string of springs 26 b, thefour-layered fabric impermeable to airflow may be used in any string ofspring shown or described herein, such as strings 26 a used in pocketedspring assembly 12 a or strings 26 used in pocketed spring assembly 12.

FIG. 14 illustrates an apparatus 90 b for conducting a method of makingthe fabric for use in the strings of springs shown and described hereinor for any other bedding or seating product, including the productsdescribed in U.S. Pat. No. 9,968,202.

Referring to FIG. 14, the method comprises providing a source 92 of thefirst protective layer of polypropylene non-woven fabric which may be aroll of polypropylene non-woven fabric or any other source. A web of theprotective polypropylene non-woven fabric 76 from the source 92 ispassed around a roller 94 and into a laminator 96. The method furthercomprises providing a source 98 of the middle airtight layer ofthermoplastic polyurethane film which may be a roll of the film or anyother source. A web of the airtight thermoplastic polyurethane film 78from the source 98 is passed around a roller 100 and into the laminator96. The method further comprises providing a source 102 of the thirdsound attenuating layer of lofted needle punch polyester fiber batting,which may be a roll of the batting or any other source. A web of thesound attenuating material such as lofted needle punch polyester fiberbatting 80 from source 102 is passed around a roller 104 and into thelaminator 96. The method further comprises providing a source 95 of asecond protective layer of polypropylene non-woven fabric which may be aroll of polypropylene non-woven fabric or any other source. A web of theprotective polypropylene non-woven fabric 76 from the source 95 ispassed around a roller 97 and into a laminator 96.

The method further comprises providing a source 106 of glue which may bea roll of the glue available from Hanes Industries of Conover, N.C. Aweb of the glue 108 from source 106 is passed around a roller 110 andinto the laminator 96. The web of glue 108 is located between the web ofsound attenuating material such as lofted needle punch polyester fiberbatting 80 and the web of airtight material such as thermoplasticpolyurethane film 78. Once inside the laminator 96, the web of glue 108is heated so it melts to secure the sound attenuating web of loftedneedle punch polyester fiber batting 80 and the airtight web ofthermoplastic polyurethane film 78 together. Residual heat from thelaminator 96 may temporarily secure the web of the polypropylenenon-woven fabric 76 to the middle airtight web of thermoplasticpolyurethane film 78 to create a four-layered web 112 b, which is passedbetween presser rollers 114 to further secure the four layers togetherinto a finished fabric 116 b shown in detail in FIG. 15. As shown inFIG. 14, a cutter 118 may be used to cut the four-layered finishedfabric 116 b to a desired size. Alternatively, the four-layered finishedfabric 116 b may be rolled into a roll 120 b after being cut.

FIG. 16 illustrates a slightly different apparatus for practicing asimilar method of manufacturing the four-layered impermeable fabric 116b shown in FIG. 15. This method of manufacturing finished four-layeredimpermeable fabric web 116 b uses a glue sprayer 130, which may applyglue to one surface of the web of thermoplastic polyurethane film 78between the web of sound attenuating lofted needle punch polyester fiberbatting 80 and the airtight web of thermoplastic polyurethane film 78before entering the laminator 96. Once inside the laminator 96, the gluemay be heated so it melts to secure the web of sound attenuating loftedneedle punch polyester fiber batting 80 and the airtight web ofthermoplastic polyurethane film 78 together. Heat from the laminator 96melts the glue to create a four-layered web 112 b, which is passedbetween presser rollers 114 to further secure the four layers togetherinto the finished fabric 116 b shown in detail in FIG. 15. As shown inFIG. 16, a cutter 118 may be used to cut the finished four-layeredimpermeable fabric 116 b to a desired size. Alternatively, the finishedfour-layered impermeable fabric 116 b may be rolled into a roll 120 bafter being cut.

Although not shown, a second sprayer may be incorporated into the systemor apparatus to apply glue to both sides of the airtight web ofthermoplastic polyurethane film 78 before the webs pass through thelaminator 96.

FIGS. 17 and 18 illustrate a different apparatus for practicing adifferent method of manufacturing the four-layered impermeable fabric136 b shown in FIG. 18. This method of manufacturing finishedfour-layered impermeable fabric web 136 b uses an ultrasonic laminator132, which may weld four incoming webs of material together withultrasonic welds 134. As shown in FIG. 17, one of the incomingprotective webs of polypropylene non-woven fabric 76 is welded to theairtight web of thermoplastic polyurethane film 78 and the otherincoming protective web of polypropylene non-woven fabric 76 is weldedto the sound attenuating web of lofted needle punch polyester fiberbatting 80. The ultrasonic laminator 132 joins the four webs at selectlocations 134 to create a four-layered impermeable fabric web 136 bshown in detail in FIG. 18. As shown in FIGS. 14 and 16, a cutter 118may be used to cut the finished four-layered impermeable fabric web 136b to a desired size. Alternatively, the finished fabric 136 b may berolled into a roll as shown in FIGS. 14 and 16.

The various embodiments of the invention shown and described are merelyfor illustrative purposes only, as the drawings and the description arenot intended to restrict or limit in any way the scope of the claims.Those skilled in the art will appreciate various changes, modifications,and improvements which can be made to the invention without departingfrom the spirit or scope thereof. The invention in its broader aspectsis therefore not limited to the specific details and representativeapparatus and methods shown and described. Departures may therefore bemade from such details without departing from the spirit or scope of thegeneral inventive concept. The invention resides in each individualfeature described herein, alone, and in all combinations of thosefeatures. Accordingly, the scope of the invention shall be limited onlyby the following claims and their equivalents.

What is claimed is:
 1. A bedding or seating product comprising: apocketed spring assembly comprising a plurality of parallel strings ofsprings joined together, each of said strings of springs comprising aplurality of individually pocketed springs, each of said strings ofsprings comprising a piece of fabric joined along a longitudinalsegmented seam, first and second opposed plies of fabric being onopposite sides of the springs, a plurality of pockets being formed alonga length of said string of springs by transverse segmented seams joiningsaid first and second plies, at least one spring being positioned ineach said pocket, wherein the piece of fabric comprises multiple layersincluding a sound attenuation layer between layers of non-wovenpolypropylene, each of the segmented seams having gaps between segmentsof the seams such that upon being subjected to a load, the gaps increasein size, allowing more air inside the pocket to exit the pocket;cushioning materials; and an upholstered covering encasing said pocketedspring assembly and cushioning materials.
 2. A pocketed spring assemblyfor use in a bedding or seating product, the pocketed spring assemblycomprising: a plurality of parallel strings of springs joined together,each of said strings of springs comprising a plurality of individuallypocketed springs, each of said strings of springs comprising a piece offabric joined along a longitudinal segmented seam, first and secondopposed plies of fabric being on opposite sides of the springs, aplurality of pockets being formed along a length of said string ofsprings by transverse segmented seams joining said first and secondplies, at least one spring being positioned in each said pocket, whereinthe piece of fabric comprises multiple layers including a soundattenuation layer between layers of non-woven polypropylene, each of thesegmented seams having gaps between segments of the seams such that uponbeing subjected to a load, the gaps increase in size, allowing more airinside the pocket to exit the pocket.
 3. The pocketed spring assembly ofclaim 2 wherein the piece of fabric further comprises a layerimpermeable to airflow.
 4. The pocketed spring assembly of claim 3wherein the piece of fabric comprises four layers.
 5. The pocketedspring assembly of claim 4 wherein at least one of the layers isimpermeable to airflow.
 6. The pocketed spring assembly of claim 2wherein only one of the layers is impermeable to airflow.
 7. Thepocketed spring assembly of claim 2 wherein the non-woven polypropylenelayers are outer protective layers on opposite sides of the piece offabric.
 8. The pocketed spring assembly of claim 2 wherein the soundattenuating layer comprises needle punch polyester fiber batting.
 9. Afabric for use in a pocketed spring assembly, said fabric comprising: afirst layer of protective material; a second layer of thermoplasticpolyurethane film impermeable to airflow; a third layer of soundattenuating material comprising needle punch polyester fiber battingsecured to the second layer to prevent noise when the pocketed springassembly is compressed and expanded, wherein the fabric is oriented suchthat the first layer of protective material is closest to springssurrounded by the fabric; a fourth layer of protective material.
 10. Thefabric of claim 9 wherein the second and third layers are gluedtogether.
 11. The fabric of claim 9 wherein the fabric forms a pocket ofthe pocketed spring assembly, the pocket surrounding a spring inside thepocket, the first layer being closest to the spring.
 12. The fabric ofclaim 11 wherein the second layer is sandwiched between the first andthird layers.
 13. The fabric of claim 9 wherein the four layers arelaminated together.
 14. The fabric of claim 9 wherein the fabric formsmultiple pockets of a string of springs for use in the pocketed springassembly, each pocket surrounding at least one spring inside the pocket.15. A method of making a fabric for use in a pocketed spring assembly,said method comprising: creating a stack comprising opposed layers ofprotective material, a middle layer impermeable to airflow, a soundattenuating layer and a glue layer between the middle layer impermeableto airflow and the sound attenuating layer; passing the stack through alaminator to create a finished fabric; and rolling up the finishedfabric.
 16. The method of claim 15 wherein the glue layer melts in thelaminator.
 17. The method of claim 15 wherein the sound attenuatinglayer is secured to the middle layer by the glue to create a sounddampening layer in the finished fabric.
 18. A method of making apocketed spring assembly for use in a bedding or seating product, themethod comprising: joining a plurality of parallel strings of springstogether, each of said strings of springs comprising a plurality ofindividually pocketed springs, each of said strings of springscomprising a piece of fabric joined along a longitudinal seam, first andsecond opposed plies of fabric being on opposite sides of the springs, aplurality of pockets being formed along a length of said string ofsprings by transverse seams joining said first and second plies, atleast one spring being positioned in each said pocket, wherein the pieceof fabric is impermeable to airflow and comprises outer layers ofpolypropylene non-woven material and a sound attenuating layer betweenthe outer layers, but air inside the pocket exits and enters the pocketthrough gaps between segments of the seams.
 19. The method of claim 18wherein the piece of fabric further comprises a layer of thermoplasticpolyurethane film impermeable to airflow.
 20. A method of making apocketed spring assembly, the method comprising: joining a plurality ofparallel strings of springs together, each of said strings of springscomprising a plurality of individually pocketed springs, each of saidstrings of springs comprising a piece of fabric joined along alongitudinal seam, first and second opposed plies of fabric being onopposite sides of the springs, a plurality of pockets being formed alonga length of said string of springs by transverse segmented seams joiningsaid first and second plies, at least one spring being positioned ineach pocket, wherein the piece of fabric comprises a layer impermeableto airflow between two protective layers, so the fabric allows air toexit and enter the pocket only through gaps between segments of theseams and the piece of fabric comprises a layer of fiber batting forsound attenuation between two protective layers.
 21. The method of claim20 wherein the protective layers are made of the same material.